master s ptm - plasmaserv

Product Training Material (PTM)

Master S 400/500

Portable power for heavy-

duty performance

Master S 400 / S 500 2

Benefits Master S 400A & 500A

• Powerful

• Compact

• Portable

• Reliable

• Easy to use

• MMA WPSs as option

• MIG/MAG WPSs as option

Master S 400 / S 500

1. Sturdy grip handle

2. Tough plexiglas cover

3. Simple and clear control panel

4. Easy-to-use DIX connectors for

MMA welding & earth cables

and for TIG torch connector

5. Shockproof casing

3

Portable power for professionals

1 2

3

4

5


Portable MMA welding power for professionals Designed for high performance professional welding

• Powerful and portable MMA power source

• TIG welding as option

• For professional workshop and site use

• Suits for all MMA electrode types

• Models including cellulose welding characteristic are also

available

• Significant welding capacity 400A/500A at 60% ED

• High power factor 0.90 and efficiency 0.89 at 100 %

• Robust structure for heavy-duty site use

• Reversed rotation direction of cooling fan

4


Electrode diameter (mm) Rutile E6013 (A) Basic E7018 (A)

1.6 30–60 30–55

2.0 50–70 50–80

2.5 60–100 80–110

3.25 80–150 90–140

4.0 100–200 125–210

5.0 150–290 200–260

6.0 200–385 220–340

7.0 280–410

Portable MMA welding power for professionals

5

Power source’s cooling fan operates in

reverse rotation direction to keep

the machine’s insides cleaner

Electrode welding parameter table


Portable MMA welding power for professionals Master S series is all about ease-of-use and performance

• Powerful 400 A or 500 A power source

• Provides great welding results

• Pleasurable welding experience

• For both mains and generator powered use

• Wide voltage network tolerance

• Protected against input voltage variations

• 380V - 440V / ±10%

• Recommended generator size / max MMA current:

• For Master S 400 25 kVA

• For Master S 500 30 kVA

• In generator use, note generator use mode ( Setup )

• Integrated VRD, Voltage Reduction Device

• Compact and light in weight

• Makes transportation and site management easy

6

Master S 400 / S 500 7

Display panel Master S display panel is designed for clear visibility

• Protected see-through plexiglas cover against:

• Scratching, dust, moisture, sand and spatters

• Function selections and symbols are clear

• Display with anti-glare features

• Large and easy-to-read numbers on display

• Green colour stands out in workshop conditions

• Good visibility also through an automatic welding lens

• Display is positioned on a optimal angle for best visibility

• Improve work ergonomics

• Setting and adjustment is simple with gloved hands

• Only needed functions for daily use are presented to the welder

• More selections in machine Setup

Weld data after welding

• Display shows average amps and voltage of the last weld

• Weld data is only displayed if welding cycle lasts over 5 seconds

Master S 400 / S 500 Master S 400 / S 500 8

Indicator lights

ON indicator

• Light indicates that power source is ON

Overheating Indicator

• Light indicates if machine is overheated

Overheating indicator


Indicator lights

VRD activation indicator light • VRD is Voltage Reduction Device

• VRD function drops OCV (Open Circuit Voltage)

• Safety feature, reduces risk of electric shock

• Such as closed or damp spaces

• VRD activation from Setup

• Solid green VRD light:

• VRD is in use, OCV is under 35 V

• Blinking red VRD light:

• VRD is in use, OCV is over 35 V

• VRD operation failure, contact Kemppi Service

• No VRD light

• VRD selection from Setup is OFF

• Welding in progress

Overheating indicator


Special technology features include hot start and arc force adjustment

• Optimised starts and arc control with all electrode types

• Guaranteeing flawless and stable weld pool control

AntiFreeze feature operates if MMA electrode is sticking to the work piece

• Function ON/OFF selection can be made in machine Setup

10

Portable power for professional MMA welding

Arc force and hot start have stepless regulation


Drops welding current to minimum amps in case if electrode sticks to weld

piece.

• Safety feature, decreases risk

for fire and hand burn damages

• Better MMA electrode re-ignition

& reuse, less electrode coating

damage.

11

Portable power for professional MMA welding

Automatic AntiFreeze operation in MMA arc

Master S 400 / S 500 12

MMA arc force

Correct arc force for all MMA electrode types

• Keeps MMA arc stable, affects the roughness of arc

• Arc force set also depends on weld case

• Display indicates the arc force set by numbers

• Regulation scale -9…0…9

• Requested arc behaviour with low weld spatter

• Keeps arc stable also with short arc length

• Good welding characteristics even with low

welding current. Center

Welding current regulation knob

Master S 400 / S 500 13

MMA arc force Correct arc force for all MMA electrode types

• Soft arc ( - 9 )

• Rutile coated MMA electrodes

• Basic arc set ( 0 ) Center

• Basic coated MMA electrodes

• Hard arc ( 9 )

• Vertical down MMA electrodes

• Cellulose coated MMA electrodes t/ms

I / A

0

Hard arc

Soft arc

Basic arc set

Current rising angle and height

determines the roughness of the arc

Master S 400 / S 500 14

MMA hot start

• Easy to start welding

• Optimised MMA arc starts and arc control

• Use with all electrode types and diameters

• Different base materials

• Material thickness

• Welding positions

• “Difficult to weld” MMA electrodes, e.g.

high Ni-alloys MMA electrodes

Master S 400 / S 500 15

MMA hot start

• Guaranteeing flawless and stable weld pool control

• Improves MMA weld quality in various welding applications

• Decreases risk of weld start defects

• Displays numeric indication of ignition pulse height/length

• Regulation scale in display min 0, normal 5, max 10

• Use 0…5 ignition pulse with MMA Ss rutile electrodes.

0

5

10 I

t

MMA hot start

operation principle

Master S 400 / S 500 16

Setup

Display panel indicate done activations in Setup mode

• Remote key´s long press > 5 s

opens Setup mode, display text “Set” shown

• Select wanted Setup parameter

by short presses of Remote key

• Turn Setup parameter selector to wanted

set value, note Factory set table

• Return to welding with long press of

Remote key, auto save to memory

Open/close Setup with

long press, in normal use

Remote control On/Off

Setup

parameter

selector

Master S 400 / S 500 17

Setup parameters

Name Function Description Factory default Adjustment range

Ant. Antifreeze

If Antifreeze selection is On, the

machine cuts off the power and

protects the electrode if sticking

occurs during the welding On On/OFF

Cab. Long cables

Long cable mode for welding

circuits of 50 m and longer (max.

80 m) OFF On/OFF

Gen. Generator

Generator mode for generator

use and fluctuating mains

networks OFF On/OFF

CU CV mode CV mode selection OFF On/OFF

rc Remote selection

Remote operation mode.

Selection between analog and

wireless remote controllers

(R10/R11T) r10 r10/r11

rcL

Remote low current

limit

Limits the remote adjustment

range. Allows more exact remote

adjustment. 30 30–MAX

rcH

Remote high current

limit

Limits the remote adjustment

range. Allows more exact remote

adjustment. MAX 30–MAX

Urd VRD selection

Reduces open circuit voltage

below 35V OFF

Fac.

Restore factory

settings

Restores setup and panel

settings to factory default OFF rES/OFF

Advanced control panel

Master S 400 / S 500 18

TIG convenience

Trusted Kemppi TIG torches for quality TIG welds

Made of the best materials

• Lift TIG arc ignition

• Ensures basic TIG welding tasks

• TTM 15 V BC

• 150 A / 35 %

• 4.0 meters in length

• Equipped with manual gas valve

• Equipped with large DIX current connector

Master S 400 / S 500 19

LiftTIG arc ignition Can be used with sharpened TIG electrode

• Ignition current won’t destroy the electrode’s sharp head

• Note the polarity change in DC TIG welding:

• TIG torch connection to power source minus (–) pole

TTM 150V BC TIG torch using procedure

• Open TIG torch gas valve

• Ignite the arc touching the work piece lightly with TIG electrode

• In lift TIG, ignite by lifting the electrode that is resting on the work piece

• Generally used TIG welding arc length is TIG electrodes Ø…½ Ø

• In the moment of TIG electrode contact the current is low

• TIG electrode release is easy because of low ignition current

• Fast automatic current rise to the set welding current

• If electrode contact with the work piece exceeds 1 second

• Automatic shutoff prevents TIG electrode damage

• Stop welding by lifting electrode and the arc will be extinguished

• Disturbance-free applications in EMC sensitive environments

• Interference free arc

• Safety

I

t

Welding Current

Ignition Current


• HF or Lift TIG arc ignition in DC TIG with LT 250

• Carbon arc gouging

• MIG/MAG welding with ArcFeed

• Parent power supply for Kemppi voltage sensing

wire feed systems and in-line TIG solutions

• Parent power source for MIG together with

ArcFeed voltage sensing wire feeder

• Two MasterTIG LT 250 TIG units can be

powered by one Master S 400/500.

20

Versatile power for different applications

Master S 400 / S 500 21

MasterTIG LT 250

Master S power supplies are also suitable for Kemppi in-line TIG solutions

• MasterTIG LT 250 offers needed modern TIG machine functions

Master TIG LT 250 A DC TIG / MMA @ 35% ED

• No mains voltage power cable or control cable

• Compact size and weight, only 12.6kg

• Remote current control options

• HF or Lift TIG arc ignition

• Digital display for parameter readout

• Gas flow meter fitted as standard

• Pre and post-gas flow control

• Up/down slope control timers

• 2T and 4T trigger latching

• Kemppi 2+ year warranty

MasterTIG 250 LT

operation panel

MasterTIG 250 LT with

TIG torch connected


Carbon arc gouging electrode holder GT 4000 is designed for use with

either round or flat carbon electrodes. GT 4000 with 2.1 m cable 6285400.

22

Carbon arc gouging

• Master S 400/500 is recommended to be used for carbon arc gouging

in CV mode

• For weld repairs and metal cutting

• Opening of root pass from weld joint’s backside

• Also for weld groove edge’s preparation

• Notice need for compressed air requests

• Note: Constant voltage (CV) mode is recommended to be used with

carbon arc gouging. In CV mode the voltage is adjusted.

Master S 400 / S 500 23

Carbon arc gouging

• Current/voltage settings for different CAG electrode Ø ( round profile):

Carbon arc gouging in progress

Electrode Voltage (V) / CV Mode Amperage (A) / MMA mode

6.35 mm (1/4”) 36–45 V 170–330 A

8 mm (5/16”) 39–45 V 230–450 A

9.5 mm (3/8”) 43–45 V 300–500 A

Master S 400 / S 500 24

Using CV mode for MIG/MAG welding • Function changes power source from CC (Constant

Current) characteristics to CV mode

• CV (Constant Voltage) characteristics are stable

regardless of amperage settings

• Results relatively stable V/A characteristics curve

• MIG/MAG machines are typically CV characteristics

machines

• Master S series power sources can be used with

ArcFeed for MIG/MAG welding

• CV characteristics activation from Setup

• MMA VRD selection must be OFF

• If CV mode is activated MMA and

TIG welding are OFF

• Operate on MIG/MAG spray arc welding

• Solid wires

• FCW (Flux Cored Wires) and MCW

(Metal Cored Wires)

• Self-shielded FCW / Gasless wires ArcFeed 300 and ArcFeed 200


ArcFeed technical specifications

• Wire feed mechanism is 4-wheel drive

• Wire feed speed range is 0…18 m/min (25 m/min)

• Wire feeders are equipped with welding gun EURO connector

• Welding wire types/diameters:

• Flux-cored wires Ø1.2 … Ø2.0 mm

• Solid wires Ø1.0 … Ø1.6 mm

• Self-shielded FCW ( e.g. AWS E71T-11 / E 71T8 Ni1 ) Ø1.6 … Ø2.0 mm

• FCW & Self-shielded FCW with model 300P, max Ø2.4 mm

Kemppi ArcFeed 200 300 & 300RC 300P

Rated power 150 W 150 W 150 W

Load capacity 100%

ED 300A 300A 300A

Spool size 200 mm 300 mm 300 mm

Dimensions Length 510 mm 590 mm 590 mm

Width 200 mm 240 mm 240 mm

Height 310 mm 445 mm 445 mm

Weight 12 kg 15 kg 15 kg

Master S 400 / S 500 26

Remote control convenience

Remote control adds convenience and cost efficiency

• R10 and wireless R11T remote control options

• R10 (6185409) and wireless R11T (6185442)

• Increase machine flexibility and ease-of-use

• For welding production and site work

• For long distances

• For difficult to access weld joints or welding jobs

• Remote control allows convenient welding current

setting

• Accurate current setting according to welder’s

request

• Eases welder’s work and improves welding productivity

Wireless R11T

remote control

in regulation use

Remote control connector

and On/Off switch are

located on the back of the machine

R10 and R11T

remote controls

Master S 400 / S 500 27

Wireless remote control R11T in use

• Activate wireless remote by choosing ‘r11' from panel's Setup Menu

• Touch grounded work piece with the tip in R11T remote control’s bottom

• Keep MMA electrode connected to remote’s contact surface during regulation

• Set desired welding current with R11T remote controls control knob

• Master S power source’s display indicates set welding current

NOTE! VRD mode must be switched OFF in wireless R11T use.

Wireless remote control does not operate when VRD is ON.

Wireless remote control R11T improves

welder’s work quality and productivity

TWQM™ Total Welding Quality Management

28

Master S 400 / S 500 29

WPS for consistent quality

Welding Procedure Specifications (WPS)

• Provide practical welding specs/welding guide

• For repeatable and uniform quality welds

• Accordance with European Committee for

Standardization

• Mandatory from 07/2014 in EU countries

• Following WPS is a prerequisite for CE marking

Read more from our website www.kemppi.com/wps

Master S 400 / S 500 30

CE marking with Kemppi WPS package

Kemppi is the first welding machine manufacturer

in the world to introduce MMA Welding Procedure

Specifications (WPS) for construction site work.

• Choose from cost-effective standard WPS packages

or ask for requirement-specific WPS packages tailored

to your manufacturing needs

• Cost-effective package solutions to comply with

EU regulations

• Compatible with all MMA welding machine brands

• Compatible with all MIG/MAG and MMA welding

MMA and MIG/MAG

WPS folder packages


Kemppi standard WPS package for MMA welding

Fillet welds WPS number Process Weld type Joint type Material group Filler material Material thickness (mm) Welding position Weld details Throat thickness (mm)

WPS 111-FW-1 111 P/T FW 1.1/1.2 3…7 PA, PB sl 3…5

WPS 111-FW-2 111 P/T FW 1.1/1.2 3…7 PC sl 3…5

WPS 111-FW-3 111 P/T FW 1.1/1.2 3…7 PD sl 3…5

WPS 111-FW-4 111 P/T FW 1.1/1.2 3…7 PF sl 3…5

WPS 111-FW-5 111 P/T FW 1.1/1.2 8…12 PA, PB sl 3…5

WPS 111-FW-6 111 P/T FW 1.1/1.2 8…12 PC sl 3…5

WPS 111-FW-7 111 P/T FW 1.1/1.2 8…12 PD sl 3…5

WPS 111-FW-8 111 P/T FW 1.1/1.2 8…12 PF sl 3…5

WPS 111-FW-9 111 P/T FW 1.1/1.2 6…10 PA,PB ml no restriction

WPS 111-FW-10 111 P/T FW 1.1/1.2 6…10 PC ml no restriction

WPS 111-FW-11 111 P/T FW 1.1/1.2 6…10 PD ml no restriction

WPS 111-FW-12 111 P/T FW 1.1/1.2 6…10 PF ml no restriction

WPS 111-FW-13 111 P/T FW 1.1/1.2 11…16 PA, PB ml no restriction

WPS 111-FW-14 111 P/T FW 1.1/1.2 11…16 PC ml no restriction

WPS 111-FW-15 111 P/T FW 1.1/1.2 11…16 PD ml no restriction

WPS 111-FW-16 111 P/T FW 1.1/1.2 11…16 PF ml no restriction


Kemppi Standard WPS package for MMA welding

Butt welds

WPS number Process Weld type Joint type Material group Filler material Material thickness (mm) Welding position Weld details

WPS 111-BW-1 111 P/T BW 1.1/1.2 3…5 PA sl

WPS 111-BW-2 111 P/T BW 1.1/1.2 3…5 PC sl

WPS 111-BW-3 111 P/T BW 1.1/1.2 3…5 PE sl

WPS 111-BW-4 111 P/T BW 1.1/1.2 3…5 PF sl

WPS 111-BW-5 111 P/T BW 1.1/1.2 5…8 PA ml

WPS 111-BW-6 111 P/T BW 1.1/1.2 5…8 PC ml

WPS 111-BW-7 111 P/T BW 1.1/1.2 5…8 PE ml

WPS 111-BW-8 111 P/T BW 1.1/1.2 5…8 PF ml

WPS 111-BW-9 111 P/T BW 1.1/1.2 6…16 PA ml

WPS 111-BW-10 111 P/T BW 1.1/1.2 6…16 PC ml

WPS 111-BW-11 111 P/T BW 1.1/1.2 6…16 PE ml

WPS 111-BW-12 111 P/T BW 1.1/1.2 6…16 PF ml

Master S 400 / S 500 33

Technical data for Master S 400/500

Master S 400 (also Cel) 500 (also Cel)

Connection voltage 3~50/60 Hz 380 – 440 V (-10 %…+10 %) 380 – 440 V (-10 %…+10 %)

Rated power at max. current 60 % ED 20kVA 26 kVA

Fuse (delayed) 25 A 35 A

Output at 40 °C MMA 60 % ED 400 A / 36 V 500 A / 40 V

100 % ED 310 A / 32.4 V 390 A / 35.6 V

Output at 40 °C TIG 60 % ED 400 A / 26 V 500 A / 30 V

100 % ED 310 A / 22.4 V 390 A / 25.6 V

Max welding voltage 400 A / 48 V 500 A / 46V

Stick electrodes ø 1.6...6.0 mm ø 1.6…7.0 mm

Welding current control stepless stepless

Power factor at 100 % 0.90 0.90

Efficiency at 100 % 0.89 0.89

Degree of protection IP23S IP23S

Operating temperature range -20…+50 °C -20…+50 °C

EMC class A A

Minimum short circuit power

SSC of supply network* 4.0 MVA 4.0 MVA

RSCE 214 235

External dimensions L x W x H 570 x 270 x 370 mm 570 x 270 x 370 mm

Weight 20.5 kg 23.5 kg

Master S 400 / S 500 34

Order information

SP007023 Slide bars

Master S 400 6321400

Master S 400 Cel (cellulose welding

characteristic) 632140001

Master S 500 6321500

Master S 500 Cel (cellulose welding

characteristic) 632150001

Welding cable 50 mm², 5 m 6184501H

70 mm², 5 m 6184701H

Earth return cable 50 mm², 5 m 6184511H

70 mm², 5 m 6184711H

Slide bars SP007023

Remote control R10 5 m 6185409

10 m 618540901

Wireless remote control R11T 6185442

TTM 15 V BC 4 m 627143201

Master S 400 / S 500 35

Troubleshooting The control panel will display any errors of the system. Error code numbers are shown

in the display and can be compared to the table below.

Power On light is not illuminated

• There is no electrical power to the machine.

• Check the mains electrical supply is connected.

• Check the mains fuses, replace blown fuses.

• Check the mains cable and plug, replace defect parts.

• The machine is not welding properly. Welding creates spatter. The weld joint is porous or power supply

is insufficient.

• Check the welding parameter settings and adjust if needed. See welding parameter table on

page 9.

• Check that the earth return clamp is properly fastened and that earth return cable has no

defects. If necessary change the clamp location and replace defective parts.

• Check the welding cable and connector. Tighten the connection(s) and replace defective parts.

Power source overheating pilot lamp is illuminated

• Power source has exceeded the designed working temperature. Fans are running and the machine is

in a cooling down cycle. The machine will reset automatically.

• Check that there is enough free space around the machine for cooling air circulation.

• In some cases when error occurs, the machine turns off. Then user must turn the main switch off

and on again.

• Check that welding circuit is open.

Master S 400 / S 500 36

Control panel error codes

Error 1 (E1) Power source is not calibrated. Calibrate power source.

Error 2 (E2) Undervoltage Check the mains network connection and fuses.

Error 3 (E3) Overvoltage Check the mains network connection and fuses.

Error 4 (E4)

Overheating. Also the overheating pilot lamp is on.

Machine drops welding current for 30 s. If error

conditions still apply:

Machine stops welding. Ensure free air flow. Let the machine cool down.

Error 5 (E5) ---

Error 6 (E6) ---

Error 7 (E7) NTC warning. (IGBT overheating). Machine drops

welding current. Ensure free air flow. Let the machine cool down.

Check the environment temperature.

Error 8 (E8) NTC error. (IGBT overheating). If error conditions

(Err7) still apply:

Machine stops welding

(model A)

Machine shuts down

(model R). Ensure free air flow. Let the machine cool down.

Check the environment temperature.

Error 9 (E9) Mains network phase alarm. Check the mains network connection and fuses. If

connected to generator check setup jumper Gen.

Error 10 (E10) ---

Error 11 (E11) VRD error.

Error 12 (E12) Power source is locked. Too long short circuit.

Machine stops welding. Avoid long short circuits (20 s).

Error 13 (E13) Wrong panel type. Check the panel.

Error 14 (E14) Current feedback is missing. Contact Kemppi service representative.


Thank You!

37

master s ptm - plasmaserv

Documents